Method of and apparatus for packaging elongated articles such as nipples



C. E. CLOUD ET AL METHOD OF AND APPARATUS FOR PACKAGING Nov. 21. 1967vELONGATED ARTICLES sucn As NIPPLES 3 Sheets-Sheet 1 Filed Aug. 11, 1964INVE NTO RS CHARLES E. CLOUD RICH ARD (a. KINC'A QJOE OPZ ATTOR NEYS C.E. CLOUD ET AL METHOD OF AND APPARATUS FOR PACKAGING Nov. 21, 1967ELONGATED ARTICLES SUCH AS NIPPLES 3 Sheets-Sheet 2 Filed Aug. 11, 1964INVENTORS CHARLES E CLOUD RiCHARD C7. K\N(a BY a; a wfl? AT TOR N E SNov. 21, 1967 c. E. CLOUD ET AL METHOD OF AND APPARATUS FOR PACKAGINGELONGATED :ARTICLES SUCH AS NIPPLES 3 Shets-Sheet 5 Filed Aug. 11, 1964INVENTORS CHARLES E. CLOUD RKHARD 6. KlNC-A A TORNEYS United States latent Ofit'ice 3,353,329 Patented Nov. 21, 1967 3 353 329 METHOD or ANDAPlARATUS FOR PACKAGING ELONGATED ARTICLES SUCH AS NIPPLES Charles E.Cloud, Wilmette, and Richard G. King, Chicago, 111., assignors to CloudMachine Corporation,

Skokie, 111., a corporation of Delaware Filed Aug. 11, 1964, Ser. No.388,800

6 Claims. (Cl. 53-30) g The present invention relates generally to a newand improved method and apparatus for manufacturing contoured articlesor cups and/ or packages utilizing the cups as a component part thereof.This invention also relates to a new and improved packaging machine andmethod for the packaging of articles such as nipples and the like. Inexperiments with the packaging of articles of an elongated type, such asnipples, with a stretchable material or film, it has been found thatwhen the material is stretched and drawn into a cup-shaped die to form aseries of elongated cups, the bottom or central area of each of the cupsis stretched to a greater extent and is formed with a smallercross-sectional thickness than a side wall area. When articles arepackaged in elongated cups of this type, it has been found that there issome tendency for the packages to rupture due to the thinness of thematerial and due to the fact that the bottom of the cups are subjectedto greater handling stresses in subsequent packaging operations and bythe purchasing public.

In order to provide a new and improved cup or package which can moreeffectively withstand handling stresses without having to use thickermore expensive type films, a new and improved method and apparatus hasbeen developed whereby the material is stretched along a side area ofeach cup in a controlled manner so that the thickness of the cup can becontrolled. Packages or cups formed having a thicker bottom are capableof withstanding greater handling stresses and are less susceptible torupture.

An important object of this invention is to provide a new and improvedmethod and apparatus for manufacturing cups and/ or packages embodyingthe cups whereby the thickness of the side walls and the thickness ofthe bottom of the cups can be controlled.

Still another object of this invention is to provide a new and improvedcup or package which is less apt to rupture when handled.

A further .object of this invention is to provide a package for anelongated article that includes a cup having a bottom with a controlledthickness that is preferably the same as or greater than the thicknessof its side wall, an article disposed in the cup and a closure strip inheat sealed assembly with a flanged open end of the cup.

According to still other more specific method features of thisinvention, a web of stretchable material is caused to be moved over aseries of heated dies. A pressure diiferential of a suitable type suchas a suction is then applied to the stretchable material causing thestretchable material to be drawn into the dies with the material beingprogressively stretched and thinned in a controlled manner as a selectedperipheral area of the Web or material is drawn into adjacency to theheated side Walls of the dies to form a strip of elongated cups.According to one preferred form of the invention, the bottoms of thecups have a thickness as large as or larger than side walls of the cups.The articles are then inserted into the cups and a closure web ofmaterial is heat sealed over open ends of the cups whereupon the websare severed to provide individually packaged articles.

Other objects and features of this invention will more fully becomeapparent in view of the followingdetailed broken away, for the packagingof articles;

FIGURE 2 is an enlarged fragmentary view partially .in sectionillustrating in full and dotted lines the manner of stretching a portionof a web of stretchable material over a package forming die;

FIGURE 3 is a side view of an elongated article encased in a packagethat is illustrated in section and is of a type produced from themachine and method illustrated in FIGURE 1; 1

FIGURE 4 is an enlarged fragmentary cross-sectional view illustratingthe manner by which the film is moved over die cups before beingprocessed to form cups for receiving articles;

FIGURE 5 is an enlarged fragmentary section similar to FIGURE 2 furtherillustrating the formed film cups and the manner of loading an articleinto one of the thus formed cups;

FIGURE 6 is an enlarged fragmentary cross-sectional view similar toFIGURE 5 illustrating one of the articles mounted in one of the filmcups;

' FIGURE 7 is an enlarged fragmentary cross-sectional view illustratingthe manner of applying a second web of material over open ends of thecups prior to scaling 'of the Webs together;

FIGURE 8 is an enlarged fragmentary side view of a cut-off mechanism forsevering packages from a continuous strip of packaged articles; andFIGURE 9 is an enlarged fragmentary partially sectioned view showing themanner in which each package may be removed from the machine.

As shown on the drawings:

The present invention is concerned with the packaging of elongatedarticles such as nipples 8 having enlarged ends 9. An apparatus ormachine 10 is provided for packaging the elongated articles or nipples 8from a continuous web 11 comprised of a stretchable material. Theapparatus 10 further includes a guide roller 12 for applying the web 11to a rotating drum 13. The guide roller 12 can be heated for heating thefilm depending on the results desired. The drum 13 has a series ofdies14 mounted about its outer perimeter. The web 11 is applied directlyagainst an outer die surface 15 as the drum is rotated in a clockwisedirection past the roller 12.

Each of the dies 14 has an elongated cup 16 that is partially defined bya flared cup side Wall 17. The flared wall hasa stepped area 18 toprovide a seat for the en'- larged end 9 of the nipple 8. The cup 16 isfurther provided with a cup bottom 19 and a suction passageway 20 isextended from the bottom 19 to an inner surface of the die 14.

Web stretching station As the drum 13 is rotated, dies 14 and thesuction passages 20 are caused to move past means for creating apressure differential across the film lying over open ends of the diesto cause the film to be moved or drawn into the dies. This means maycomprise a plug or air pressure directable against the exterior surfaceof the overlying film or a stationary suctionheader or manifold 21 as isillustrated in the drawings. The header or manifold 21 has a'suctionpipe or conduit 22 that is connected to a vacuum pump'(not shown) whichmay be of any suitable type. Heating elements are connected to the dies14 and particularly to the flared cup side wall 17 of the die cup 16 sothat the cups are continuously maintained in a heated condition duringthe operation of the machine 10.

. The die cup 16 is heated to a sufiicient temperature so that when aperipheral portion of the web or film of stretchable material moves intoadjacency to the heated die cup area or surface as a result of thepressure differential applied to the area of film overlying the open endof the the cup, the film will be heated and then progressively stretchedand thinned and allowed'to take a set andstretchedas the film is movedinto adjacency to the heated side wall of the die'cup to selectivelystretch the 'same rather than to stretch the central area z of theportion. In the practice of the method and in the operation of theapparatus or machine, the temperature of the die cup 16 will varydepending on the type of film used. There are a number of conventionalmeans that can be used to heat the inner surfaces of die cups 16 asindicated at H inFIGURE '2.

As the cups 16 are rotated past the suction manifold 21, portions of theweb are drawn into the elongated cups 16 and uniquely formed to providecontoured articles or cups 23 in accordance with important features ofthis invention. To this end, as the web is moved into the cup, theheated flared wall heats the film causing the web material to bestretched and progressively thinned to form the elongated cups 23. Theweb material can be thinned by maintaining the die side wall 17 at 230F. to 240 F. where a polypropylene film or web is used. As mentionedpreviouslyyany suitable means can be utilized to create the pressuredifferential to cause the film to be moved into the cup. Where anexternal pressure is applied to the film to urge the'filmintothe cup,the cup passage 20 is useable'as a vent to facilitate movement of thefilm into the cup. These elongated cups 23 can be linked together byintermediate strip areas 24 (FIGURE 5) or they can be individuallyformed. Each cup includes a bottom 23a, a flared sidewall 23b, a steppedarea or seat 23c, and an open end 23d. As a result of the just describedstretching and thinning operation, the side wall 23b may be verydesirably" left in a condition whereby it is thinner than thethickness'of the bottom 23a. Excellent results can be obtained by usinga polypropylene film known as the UDEL'film that is sold by UnionCarbide Plastics Co. By'practicing this method, it is possible to use a3 mil polypropylene sheet instead of a 5 mil polypropylene sheet wherebythe packaging expense may be substantially reduced. Where a 3 milpolypropylene sheet is used, the stretching operation can be controlledand excellent results can be obtained where the cup is formed having abottom 23a with a thickness of 2.7 mils and where the side wall 23b hasa thickness of 1.5 or 2 mils and where a flanged end 23 is left with athickness of approximately 3 mils. According to other features of thisinvention, the side wall and the bottom are formable so as to be of anessentially uniform thickness. Depending upon the type of materialrequired and the results desired, the film can be preconditioned forcontoured forming in the heated die cup 16. The film can be heated orchilled and the roller 12 is heatable or chillable to condition the filmin the desired manner. Where polypropylene is .used, the film can bepreheated to a temperature of 200 F.'to 400 F. or chilled to 35 F- or 40F. where preheating or chilling is desired. To load stretched cups witharticles such asfrankfurters or suppositories, the formed cups must beremoved from the hot dies and placed. into dies having a temperatureappropriate to the product being packaged. Thereafter, the cups areloaded and peripherally sealed to prevent the heat from affecting theproduct. The nipples can be loaded into a hot die as they will not beaffected by the heat. In accordance with the present invention, wherearticles are to be packaged in side-by-side relation, the shape of thedie cup can be varied to provide a die having a bottom that isessentially flat and only slightly tapered side walls so that anessentially parallel sided package can be produced. The film in theformed cup will be thinned along its parallel sides and the bottom willbe thicker than the sides.

Loader Afterthe cups 23 are for-med to shape, they are in condition toreceive the articles or nipples 8. These articles or nipples 8 can bemanually inserted into the elongated cups 23 or inserted by means of aloader 24 of any suitable'type. As illustrated, the loader 24 may be ofany suitable'type and in the illustrated form comprises a wheel that iscapable of holding the nipples on the wheel until the nipples areinserted into the cups 23.

Package closing station At the packagerclosing station, means orapparatus 25 is provided forslightly collapsing the elongated cups 23 isconnected with an air inlet passage '28 which is in turn connected to asuitable source of air pressure. As the dies 14 are rotated past the box26, the suction passage way 20 is connected with the air chamber 27enabling pressurized air to flow in a direction toward the elongatedcups 23 causing the cup bottoms 23a to be collapsed as illustrated inFIGURE 7.

Guide rollers 29 and 30, 30 are provided for applying a second web 28 ofstretchable material onto the rotating drum over the open ends 23d ofthe elongated cups 23 as the cup bottom 23a are being collapsed. A heat'sealer 31, ofany' suitable type, is provided for joining the webs 11 and28 contemporaneously asthe cup bottoms 23a are collapsed. The heatsealer 31 maybe of any suitable type capable of joining two layers orwebs of stretchable film together. In the sealing operation, it will be'appreciated that the area surrounding the open end 23d of the'cup 23is'sealed to form a continuous strip 32 of packaged nipples.

Apparatus or means 33 is provided for removing the continuous strip32from the :dies 14 which includes a roller 39 and .a driven cut-01fmechanism 34. The cutoflf mechanism 34 functions t-opull the'strip 32from the dies over the roller 39.

Cut-01f ;The' cut-off mechanism 34 includes .a rotating wheel or roll 35having a series of heated oval-shaped knives 36 about its-perimeter. Aback-up wheel or roll 37 is mounted opposite thewheel or roll-35' anddriven at the same rate. A seriesof cup receiving :pockets 38 isprovided about its circumference for receiving the cups 23 on the strip32. The circle formed by each of the knives 36 is sufiiciently large sothat as each heated knife is roated against the'bacloup wheel'37, aflanged area 23:; is cut outabout the enlarged or open end 23d of thecup completing theformation of a packaged unit or a flanged package 40.

Removal of packages A pick-up mechanism .41 is provided for removing thepackaged units or articles 40-from the cup receiving pockets 38 providedon the back-up wheel 37- of the cutoff mechanism 34. Thepick-up-mechanism comprises a wheel having circumferentially'spacedsuction heads 42 which project radially outwardlyfrom the outerperimeter of the wheel. The wheel .and the heads 42 .are rotatable atthe same rate as the wheel 37 and timed'so that the heads 42 come incontact with theend of'the packaged unit or article to withdraw the samefrom the associated pocket 38. After-the packaged'nnit .40 is removed,the suction is cutoff by.a.suitable valve arrangement .and

the package 40 is allowed to drop into a box or onto a conveyor forfurther processing.

Each suction head 42 includes an enlarged head end 43 having suctionpassages 44 therein through which suction may be applied to the end ofthe packaged unit or article. An opposite end 45 of each of the heads 42is connected by means of a suction pipe 46 to valves and to a suctionpump which may be of any suitable type. As previously mentioned, as theunits or articles 40 are removed from the pockets 38, the suctionapplied through the pipe 46 is cut olf permitting the unit or article 40to drop free into a box or onto a conveyor.

Although minor modifications might be suggested by those versed in theart, it should be understood that we wish to embody within the scope ofthe patent warranted hereon, all such modifications as reasonably andproperly come within the scope of our contribution to the art.

We claim as our invention:

1. In a method of packaging elongated articles, the steps of:

moving a web of stretchable material over a series of heated dies,causing the stretchable material to be moved into the heated dies withthe material being progressively stretched and thinned as it is hetaedby the heated side walls of the dies forming a strip of elongated cupswith bottoms of the cups having a greater cross-sectional thickness thanside walls of the cups,

attaching a closure web of material over open ends of the cups afterarticles have been inserted into the the cups providing a strip ofpackages, and separat ing the packages from one another.

2. A packaging apparatus including:

a series of heated cup-shaped dies means or applying a web ofstretchable film over open end of the dies, means for causing a pressuredifferential to be applied to the stretchable film overlying the openends of the cup-shaped dies for causing the material to be moved intothe dies and to be thinned forming cups each having a thinned stressrelieved side wall,

means for applying a second Web of material over the open end of thecup,

means for sealing the webs together closing the open end of the cup, and

a cut-01f mechanism comprising a first roll having .circumferentiallyspaced pockets for receiving the cups on the film strip and a secondco-rotating roll having a series of circumferentially spaced circularheated knives synchronized for the cutting of the webs about open endsof said pockets for forming flanged packages.

3. A cup forming apparatus including:

a series of heated cup-shaped dies means or applying a web ofstretchable film over open end of the dies,

means for causing a pressure differential to be applied to thestretchable film overlying the open ends of the cup-shaped dies forcausing the material to be moved into the dies and to be thinned formingcups each having a thinned stress relieved side Wall,

a cut-off mechanism comprising a first driven roll havingcircumferentially spaced pockets for receiving the cups on the filmstrip and a second co-rotating roll having a series of circumferentiallyspaced circular knives synchronized for the cutting of the web aboutopen ends of said pockets for forming flanged cups, and

a rotating suction roll having suction heads about its perimeter withthe suction heads being cooperable with the pockets on said first drivenroll for removing the flanged cups therefrom.

4. In a method of forming a cup, the steps of positioning stretchablesynthetic film plastic material over a heated die, and

applying a vacuum to one side of the material causing the material lyingover the die to be drawn into the die while contemporaneously causing anouter peripheral area of the material lying over the die to beprogressively engaged against'a heated side Wall area of the die andstretched and thinned leaving a central area of the material atessentially its original thickness forming a cup with a bottom having agreater cross-sectional thickness than its side wall.

5. In a method of forming a cup, the steps of:

positioning stretchable synthetic film plastic material over a heateddie, and

causing relative movement between the material and the die therebyprogressively engaging an outer peripheral area of the film against theheated side wall of the die thereby thinning the outer peripheral areaforming a cup with a bottom having a greater crosssectional thicknessthan the side wall of the cup.

6. In a method of forming contoured articles, the

steps of causing relative movement between a web of stretchablesynthetic plastic material and a series of heated dies and utilizing acombination of the movement and the heat from the heated side walls ofthe dies to progressively stretch and thin at least a portion of the Webto form a strip of contoured articles.

References Cited UNITED STATES PATENTS 2,490,781 12/1949 Cloud 53-30 X2,546,059 3/1951 Cloud 53-29 X 2,597,986 5/1952 Halstead 53-29 X2,697,314 12/1954 Stirn et al 53-30 2,880,902 4/1959 Owsen 220-82,888,787 6/1959 Cloud M 53-30 X 2,902,802 9/ 1959 Stirn et al 53-282,949,713 8/1960 Vogt 53-29 2,958,168 11/1960 Vogt 53-184 X 3,218,77611/1965 Cloud 53-30 3,220,544 11/ 1965 Lovell 206-46 GRANVILLE Y.CUSTER, ]R., Primary Examiner.

1. IN A METHOD OF PACKAGING ELONGATED ARTICLES, THE STEP OF: MOVING AWEB OF STRETCHABLE MATERIAL OVER A SERIES OF HEATED DIES, CAUSING THESTRETCHABLE MATERIAL TO BE MOVED INTO THE HEATED DIES WITH THE MATERIALBEING PROGRESSIVELY STRETCHED AND THINNED AS IT IS HEATED BY THE HEATEDSIDES WALLS OF THE DIES FORMING A STRIP OF ELONGATED CUPS WITH BOTTOMSOF THE CUPS HAVING A GREATER CROSS-SECTIONAL THICKNESS THAN SIDE WALLSOF THE CUPS, ATTACHING A CLOSURE WEB OF MATERIAL OVER OPEN ENDS OF THECUPS AFTER ARTICLES HAVE BEEN INSERTED INTO THE THE CUPS PROVIDING ASTRIP OF PACKAGES, AND SEPARATING THE PACKAGES FROM ONE ANOTHER.